Method and apparatus for manufacturing carpets



June 8, 1954 G. c'. AHIER ETAL METHOD AND APPARATUS FOR'MA MIFACTURING CARPETS Filed Oct. 17, 1950 Sheets-Sheet l June 8, 1954 G. CAHIER Erm. 680,469 METHOD AND APPARATUS FUR MANUFACTURING cARPETs Filed oct. 17, 195o l 9 Sheets-Sheet 2 4 I INVENTOR. LIN GQG' BY SSCMM AHI-cr Ans KR'ULL.

June 8, `1954 G. c. AHIER ETAL 2,680,469

METHOD AND APPARATUS FOR MANUFACTURING CARPETS Filed Oct. 17, 1950 9 Sheets-Sheet 3 svbpmmwq l amig June 8, 1954 G. c. AHIER Erm. '2,680,469

METHOD ANDl APPARATUS FOR MANUFACTURING CARPETS Filed Oct. 17. 1950 9 Sheets-Sheet 4 IN VEN TOR. (mov erwes Akku June 8, 1954 G. C. MER Em 2,680,469

METHOD AND APPARATUS FOR MANUFACTURING CARPETS Filed Oct. 17, 3.950 9 Sheets-Sheet 5 -Er im IN VEN T 0R.

QSQ, ou@ Akev HANS Kaum...

June 8, 1954 G. c. AHIER ETAL 2,680,469 METHOD AND APPARATUS FOR Filed Oct. 17, 1950 MANUFACTURING GARPETS June 8, 1954 G. c. AHIER ETAL 2,680,469 METHOD AND APPARATUS FOR MANUF Filed oct. 17. 195o ACTURING CARPETS y 1N VEN TOR. gepr tS- (mvk AKH June 8, 1954 G. c. AHlER ErAL 2,680,569

METHOD AND APPARATUS FOR MANUFACTURING cARPETs Filed oct. 17, 195o 9 Sheets-Sheet 8 Q "s n l R wk@ Hyji LAI AAL June 8, 1954 G. c. AHIER ETAL- 2,680,469

METHOD AND APPARATUS RoR MANUFACTURING cARPETs 9 Sheets-Sheet 9 Filed Oct. 17,

.III

IN VEN TOR.

A N RQSLL @Mw k +@w` k Patented June 8, 1954 UNITED sTATss METHOD AND MANUFACTU APPARATUS FOR RING CARPETS Application October 17, 1950, Serial No. 190,476

39 Claims.

This invention relates to new and useiul imprcvements in carpet manufacture.

The invention particularly concerns a device for the manufacture of carpets and especially semi-nished products required in carpet manufacturing operation, such as the so-called chenille furs. These chenille furs essentially consist of a warp chain, i. e., warp threads, having a thereto vertically arranged pile or tufting of weft threads, the so-composed chenille furs or strips being secured in closely spaced relation upon a suitable base.

The invention is addressed in particular to a device for the practice of a method for the manufacture of carpets and similar fabrics of the chenille type having a warp chain with vertically arranged cut pile or tufting weft threads. In accordance with this method, the chenille strips, i. e., the chenille fur, is not made by weaving or knitting, but rather by the cementing or bonding of the weft threads in practically right-angular arrangement to and upon the continuously moving warp threads. The weft tufting or pile which is thusly arranged or provided upon the warp or chain threads is then lifted to thereby obtain the chenille fur, the latter being thereupon arranged in closely-placed-together strips upon-a suitable base by the simple expedient of cementing the strip or strips upon the same to thereby obtain a finished carpet product. Latex solutions are primarily used for the cementing or bonding of the threads to each other or of the strips to the base.

The invention is further concerned with devices with the aid of which it is possible to obtain chenille furs or carpet fabrics in substantiallyV continuous operations whereby any interruption that may be required is solely occasioned by the necessity for exchanging Warp or weft spools. It is then further possible to print upon the chenille furs during the course of their manufacture a suitable pattern for the ultimate carpet so that it is in effect possible to manufacture the final carpet product in substantially a single operation starting with the raw yarn and an appropriate base fabric or mat. The machine, in accordance with the invention, is primarily characterized by the combination of the following elements:

(c) Means for the unreeling of the warp or chain threads from a chain beam for passage through the entire machine with a substantially I uniformly regulable speed whereby the driving motor is preferably also to furnish the drive for the circulating weft thread guide, if necessary by way of suitable gearing or transmission, prefera ly also eilecting the rotation of or guide rolls;

(b) Means for the coating of the warp threads other transport with a suitable bonding, cementing, or other similar agent; e

(c) An arrangement for supplying weft threads from suitable supply spools thereof and in a direction substantially at right angles to the direction of movement. of the chain or Warp threads;

(d) Cutting means for cutting the strip or ribbon composed of the chain threads and the thereto transversely cemented warp threads along the individual chain threads;

(e) Means for the lifting up of the weft thread pile which is cemented or bonded to the individual chain threads rso that thereby the so-called chenille fur is produced; and preferably in addition to the foregoing;

(f) Means for the bonding or cementing of the thusly produced chenille furs upon a suitable base which may be reeled oli" from a special supplyroll together with the chain or warp threads.

rlhe invention will be more fully understood and further objects thereof will appear from the following description read in conjunction with the drawings in which:

Fig. l illustrates a diagrammatic perspective view of a device constructed in accordance with the invention; Y v

Fig. la represents the diagrammatic top view of an embodiment of the drive means of the invention, where a single motor is used to drive the entire device;

Fig. 2 is a diagrammatic perspective view of an alternative embodiment of a device in' accordance with theinvention;

Fig. 3 is a diagrammatic perspective view illustrai-,ing a further alternative embodiment of a construction in accordance with the invention;

Fig. 4 illustrates a diagrammatic side View partly in section of part of the construction shown in Fig. 1;

Fig. 5 is a diagrammatic top view of part of the construction shown in Fig. l and illustrates the path of travel of the warp or chain threads carrying the weft threads and the cutting of the resulting tubular member into a substantially flat strip or ribbon;

Fig. 6 represents a diagrammatic-top view of part of the construction shown in Fig. 1 illustrating the further course of the chain or warp threads after the cutting operation as Well as showing the tracksserving the formation of the chenille fur;

Fig. 7 is a diagrammatic side view yof a portion of a construction in accordance with the invention and representing a part following in sequence that shown in Fig. 4;

Fig. 8 represents essentially a cross-sectional side view partly in section of an alternative embodiment of a construction in accordance with the invention and corresponding to the representation illustrated in Fig. 2;

Fig. 9 is a diagrammatic cross sectional view on the lines 9--9 of Fig. 10; f

Fig. 10 is a diagrammatic side viewfo Fig. 9.

Fig. l1 is a diagrammatic cross sectional view on the line lI-II of Fig. 12.

Fig. 12 is a diagrammatic sideview of Fig. 11

Fig. 13 is a diagrammatic cross sectional view on the line I3--I3 of Fig. 14. c

Fig. 14 is a diagrammatic side view of Fig. 13.

Fig. 15 is a diagrammatic top View ofthe Werl;- ing cylinder with the continuously? moving chain or warp threads thereon; Y A

Fig. 16 is a diagrammatic end View of the cylinder shown in Fig. 15, on a base;

Fig. 17 and Fig. 18 are diagrammatic side and top view ing 'cylinder shown in Figs.l 15 and "16;

19 illustrates a diagrammatic cross-sectional view taken on line Illl of Fig.l 20 of part of the cutter roll and wedge notch roll construction;

i Fig. 20 represents adiagrammaticside view of the construction shown in Fig. 19;

Fig. 21 exempliesa diagrammatic side view arrangement for the cementing ofthe chenille furs upon two superimposed vbase materials;

Figs. 22 and 23 are diagrammatic iside View representations partly in section shoungveft spool discs and vparticularly atthelj moment of the change oftheweft slpoolsjfwj gj .p Fig. 24 shows a 'diagrammatic' view partly in section of a weft spool beam; A,

Fig. 25 is a diagramm tic representation showing the Winding of n single weft lthread upon the working cylinder; 1' j l, Fig. .26 representsv a vdiagrammatic front view partly in section of the head portion'of a machine in accordance with the invention;

Fig. Z'Iillustrates a diagrammatic representation showing the fabric formed ofl the chainl or warp threads and the thereto bonded weft threads after the cuttingof the yfabric tubeg. I Fig.28 is a diagrammatic side view of a guide member 'for 'compensating length differentials of the chain threads; v v L Fig. 29a illustrates diagrammatically a print pattern as it is printed upon. the continuously movingchain thread strips or bands;

Fig.. 29h shows diagrammatically the same pattern illustrated in Fig. 29ar but on `the final carpet product;

Fig. 30 illustrates a diagrammatic representation showing the bringing together of several chenille fur `strips from a single Aplane onto a common carpet base; v Y.

Fig. 31 illustrates diagrammatically thebringing together of several chenille furstrips from different planes; Y Y.

Fig. 32 is a diagrammatic side view representation of-Fig. 3l;

yFig. V33 exemplifiesby way of diagrammatic side `View representationa `spiral winding of a chenille strip onto a carpet base;

Fig. 34 illustrates a diagrammatic iront view of the chain thread guide, the weft thread winding means and drive pulley of the construction illustrated in Fig. 1; and

Fig. 35 is a diagrammatic side view partly in section of Fig. 34. Y

As illustrated, for instance in Figs. l and 4, the chain or warp threads 2 on chain beam l PaSS representations respectively of the work- '1 over a guide roll 3 which dips with its lower surface into a trough l which is filled with a suitable bonding or cementing agent such as for example a rubber latex solution. The chain beam I may be provided with a suitable braking mechanism for the regulation of the thread tension. The chain or warp threads are coated in the trough 4 with the bonding or cementing agent and are then passed by way of the guide roll 5 to the circular chain thread guide 6. 1f desired, a press roll (not shown) may be arranged above the guide roll 5 for the purpose oi removing surplus coating material.' Alternatively, scraper combs 'I may be arranged for the chain or warp threads preceding the guide roll 5 in order to obtain a clean --uniform wetting of the chain or warp threads by the coating liquid.

Instead of coating the chain threads with the cementitious material when 'passing through a coating bath, it may be possible as illustrated in Figs. 9 and l0 to' provide a substantially annular channel 8 just prior to the chain thread guide 6 and which annular'channel is lled with the cementing or bonding material and carrying at its interior surface multiple openings `9 through which' the bonding Vmaterial may emerge;- The chain threads 2 are passed through the inside ofV this annular guide" channel along the exit nozzles for thebonding or cementitious material to be thereby coated with the bonding agent.' An alternative construction of aY bonding material applicator is shown in Figs'. 11 and l2. The bonding material is contained in the annular channel Srwhich is provided at its front and rear with the packing and stripping plates ill. Chain threads 2 are passedV through the slotted openings 1I of the annular channel and are freed from excess bonding material by passage over the stripping platesV Ill at the exit ends ofthe channels.

Itis also possible to provide a mechanism for thebonding agent impregnation or coating in accordance with theA illustrations of Figs. 13 and 14. As there shown, an annular housing I2 is provided within whichthe water wheel I3 .rotates and to a j. which the bonding material is passed through its hollow axle ifi. The annular housing I2 possesses passage apertures I l for the chain threads 2 and substantially uniformly distributed equidistantly from the center. Rotation of the Water wheel I3 which is ofthe Segner water wheel type, causes the bonding agent to be sprayed in the form of fine jets into the housing I2 thereby obtaining a wetting of the chain threads. As illustrated in the embodiment shown in Figs. 11 and 12, stripping plates I may be arranged at the exit end of the annular housing I2 for the purpose of stripping excess bonding or cementitious agents from the chain threads. Y

The chain thread guide is provided with circularly arranged apertures I5 corresponding in number to the number of chain threads, the latter being passed through these apertures. In this manner, a substantially circular tube is obtained. The chain threads are passed in this form over the Working cylinder I6, the diameter of which corresponds approximately to the diameter of the thread guide 6, and it is at this point that the weft threads I1 are added. The weft threads are on the weft spools I8 which in turn are secured on a substantially circular disc I9. The latter is rotated during the operation of the machine and the weft threads I1, reeling oi the spools I8 are in this manner spirally wound over the working cylinder I6, and thus over the continuously moving chain threads 2. For the purpose of reguassenso@ lating the tension ofithe weft threads as theylreel: off from their spools, threadl-tension regulators: are provided which rotate together with thefweft. spools. These weft thread-tension regulators' may for instance include or consistof spring* tensioned rolls or the like. Inlorder'to` assure the" bonding or cementing of the weftthreads upon the chain threads which are impregnated with the bonding or cementing agent, rolls r2I are preferably vprovided on the disc I9 and in between the weft spools and which press or bear'ag'ainsttheV surface of the working drum or cylinder I'E, thereby also providing for thesmoothed positioning of the weft threads. Working cylinder I6. is preferably a heating cylinder so as to effectV byf way of heat exchange avcoagulation or selidiicaY` tion of the cementing or bonding agent soy that the weft threads are thereafter securely ilXedvr upon the chain threads. For the purpose of avoiding a deleterious influence upon the therewith contacting threads, the working cylinder is preferably chromium plated.

Chain' threads 2 are easily shifted on workingcylinder I t out or their normal position by the winding of the weft threads I'I as is, for instance, illustrated in Fig. 15. In order to avoid suchy shifting of the chain threads and tobringthe same; again in a substantially straight position as is lindicated by broken lines in Fig. 15, it isof'advantage tc rotate the workingcylinder I6- ina substantially continuous manner so that the chain threads 2 ofthe surface of the cylinder Will be shifted substantially to the same extent in one direction as they are shiftedin the oppositel direction by the application of the weft thread I'I.

In lieu of the arrangement just described, it is also possible, as illustrated in Figs. 17 and 18, to provide above the working cylinder I 5 guide rolls 22'for two metal threads 23 which pass over-the working cylinder it in place of the two uppermost chain threads and which will be included in the winding cf the weft threads Il; Inasmuch as' these metallic threads 23 doA not, however; carry a bonding agent, no cementing together orY bond'- ng occurs of the weft threads I 'i to `these' metallic chain threads. Since, on the. other hand, the metallic chain threads 23 may be placed under' any desired tension, they will notbe shifted from their normal position by the transversely windingy weit threads I?.

After the formation of the fabric tube, a cutter' 24 cuts the saine at its periphery along thel chain threads whereupon the out material is, folded apart into a substantially liat piece of fabric' orv ribbon. If the two metallic chain threads 23 werev provided in the upper portion of the tube, the latter is cut between these metal. threads. The metal threads which have no connection with the rest of the fabric, are theny returned by WayY of` the rolls 22. The folding apart of the tube is effected with. the aid of the guide roll 25 which may be provided, if desired, with. notches. or` grooves for the positive guidance of the chainl threads. As may be seen from the drawings', the cemented or glued-on weft threads are positioned' at the underside of the continuously moving. chain threads.

In order to reduce the length of the machina. it is possible to return the ribbon which has been produced by way ofthe guide roll 25lso that the same will now move in the opposite direction being` then passed. toV the cutter ro11'2ii which is` armed with as.- many cutters 2l as correspond'to. the-number of chainthreads. Theweftthreads. are then cut with the aid ofthis cutterroll; each track elements 32.Vl

cutting being effected;y in'y between the chain threads soY that each', individual chain thread chenille fur'. 33` illustrated in the drawings.

Thecheniller furs pass from roll 28- onto the These tracks 3'2 possess a U wouldbe at toov great'a distance from each other so that itfwould not be possible to form a reasonably` close carpet product. For this reason the track 32 "to accomplish this without hinderance of tracks 32 by other such advantage to so arrange channel tracks 32' as for instance shown in Fig. 7 that the sameare: essentially provided in two of which will partially overlie each other.

For* the purpose of permanentlifting of the weft thread pile ortuftmaybe accomplished with tionalV finishing or sizingl material.- larly advantageous: inv this. respect vare of the so-called cation-active threads thatare usually composed' of wool by reason of'their: opposed electric charges.` channelsf orijtracks through thesechannels.

. Chenille furs- 33 which have been formed` in these channel# tracksv and which are The Roll 28Ypreferably carries in.v

The' 32': are also preferably heated' 36'. The base material is passed along a moistening roll 3S by way of the guide rolls 3l and 32, the moistening roll 33 dipping into the trough S which is also filled with a bonding or cementing material. Also in this case the bonding or cementing material may be rubber latex. Roll 39 which is rotated frictionally by the base material will continuously transfer an appropriate amount of the bonding or cementing agent upon the underside of the carpet base. Guide roll 31 serves simultaneously as a return roll so that the side of the base which is coated with the bonding or cementing agent will now face upward. The same passes then together with the chenille furs 33 and below the same upon the drum or cylinder 34, the chenille furs being bonded or cemented with the aid of press roller Ill upon the base surface coated with bonding or cementing material. Drum 3l! is preferably heated so that simultaneously a coagulation and thus a substantially permanent cementing or bonding of the chenille furs to the carpet base occurs. For the purpose of obtaining a sunlciently long period of coagulation, it is desirable to pass the base material together with the thereto bonded over the maximum possible circumferential length of the drum. A guide band or ribbon l2 may be provided for this purpose, the same being passed closely along the surface of drum 34 by way of the guide rolls 63 so that an intimate contact of the freshly-glued or cemented carpet material with roll il is assured. The final carpet may then be rolled up in ccnventional manner. Y

Instead of using a single base for the carpet, it is also possible, as illustrated in Fig. 2l, to use two such base materials. ln this case, the first such base 35 is preferably of a substantially porous character so that the bonding or cementing material passed onto the same by rcll Se penetrates the pores or perforations of this base. The second such base material dil is reeled off from a supply roll E and is secured from below on roll 3d to the intermediate material by way of the base 35 which is coated on both sides while the chenille furs 33 are glued to the upper side of the intermediate layer material.

The weft spool carrier i9 is rotated by a motor B2. As the pulley Si is rotated by the motor 92 it rotates pulley H2 (see 34 and 35) by means of a drive belt Sil. Pulley H2 is Iattached to the weft spool i9 which rotates .on bearing llt around the stationary chain thread guide E. The chain thread guide t consists of a drum and disk H4 which are supported by a stand il@ and are attached to the support of cutter 3.21 by rods l l l.

In the alternate embodiments (Figs. 2 and 3) drive belt 9e is attached to a pulley Ella encircling carrier arms 54.

The motor 92 may device as shown in Fig. la. The other end of the motor shaft 93 is attached to a gear box 94 which drives pulley 9G through shaft 95. Pulley Q9 attached to roller 23 is driven in the same direction as pulley 96 by a drive belt i90. Pulley 9'! on the same shaft 2s drives roller lB in the same direction by means of a belt attached directly to its pulley IM. Pulley 28 also on roller shaft 28 is connected to pulley lill on roller 25 by means of a crossed belt mi, thus roller is made to rotate in the opposite direction. Pulley H32 on shaft 25 is connected by a direct belt drive to pulley |06 on shaft 3,4 causing shaft 34. to rotate inthe same direction as shaft 25. Thus shafts 28 and |08 are caused to rotate the opposite be used to drive the entireA wr il) it is also possible to be readily rotatable upon shaft 52 direction to the rotation imparted to shafts 25 and 34. All the rollers are supported and allowed to rotate on the support plates shown in Figs. l, 2 and 3. Only one support plate is shown where the insertion of both would obstruct the view of the working parts of the device.

inasmuch as the weft spools are relatively quickly empty, the machine described up to this point will require a relatively frequent stoppage for the purpose of changing the used-up weft spools and to insert new fully-charged spools. For this reason, weft spool carrier l2 may be arranged as a double carrier, as is for instance exemplified in Figs. 22 and 23. As there shown, weft spool carrier 19 has an oppositely arranged thereto substantially congruous weft spool carrier 19a. The change or exchange of weft spools is substantially automatic when utilizing this arrangement. At first, weft spool carrier I9 rotates with its completely charged spools around working cylinder 1E. Carrier lea is then in nonengaged position, being charged with the replacement spools lea. As soon as spools i8 on carrier I9 are almost completely reeled oil, carrier Illa will begin rotation until it rotates substantially synchronously with the carrier disc 19. The moment weft thread I3 is run off from spool i8, the ends of the threads of the old spools are connected with the beginning of the threads of the new spools in a substantially automatic manner. Disc lila will now move into the position for instance illustrated in Fig. 23 forcing empty spool i3 from its spring-cushioned support by the insertion into this support of the new spool l8a. Supply disc lBa then returns and is again brought into non-engaged position and may then be once more charged by an operator with new spools.

Another embodiment of the invention, and in which a relatively frequent change of weft spools is avoided so that a longer uninterrupted operation of the machine is assured, is for instance illustrated in Figs. 2 and 8. rlhe weit threads are in this case arranged on the weft spool beam 58 having an axis in continuation of that of the working cylinder H5. Weit threads ll are passed from weft spool beam til over rotating thread guides 5l secured upon shaft E32 by way of the cross coupling 53 and carrier arms Erl and thence over suitable return rolls 55 to the working cylinder IE. The weft threads are preferably subdivided into several fields (as for example 4 or 6 fields) whereby each weft thread field is provided with a cycling thread guide 5i. instead of subdividing weft threads into individual nelds, to secure several diflerent weit thread spools upon the weft spool beam 5G.

The individual thread guides 5l are distributed at appropriate angular distances from each other along the circumference of the weft spool beam, and thus of the working cylinder la. For the purpose of obtaining reeling of the weft threads il from the weft thread beam Eril, the latter is arranged or mounted as for example with the aid of the ball bearing 56 so that the same may easily rotate along with the unreeling of the weft threads through the rotating thread guide 5l.

Fig. 24 illustrates diagrammatically the change of reeled-oif weft beam through a new one which is fully spooled. For this purpose, the two weft beams 5G and 5ta are arranged on the same shaft 52.

the easiest possible un-l While the operatively connected weft beam' 5B is being spooled olf, the spooled-oif beam 5ba crease too chain threads and the therewith coupled prois freshly reeled in the same operation. As soon as beam 56 is empty, the same is brought into the position of beam 5ta, moving the latter, which has been re-spooled in the meantime, into operational engagement,

Instead of taking the weft threads off several individual iields by Way of several thread guides, it is also possible to provide a single weft thread spool i8 from which the thread may be unreeled overhead so that this spool need not to In this case, only a single thread guide 5I 1s required, which will Wind the weft thread spirally upon the working cylinder It. shows diagrammatically such an arrangement. The weft thread Il, running o weft spool I8, passes through a thread guide herein described upon the working cylinder le and the chain threads thereon (not shown in this illustration). ever, presupposes locity of the thread guide much the speed rotational ve- 57 so as not to deof movement of the duction capacity of the machine.

When arranging a single substantially stationary weft thread spool, no changes are as such necessary for the supplying mechanism of the chain threads of the type as they have been herenabove described. If, however, several weft threads from different fields are reeled off la rotating weft beam such as weft beam 50, that side of the Working cylinder I6 on which the chain thread supply normally free. The chain threads will therefore have to the working cylinder 8 in a substantially backwards direction, that is, counter For this purpose, the working cylinder is constructed substantially hollow. The chain threadsl? will then pass (see Figs. above described embodiments of the machine, from a chain beam l over a wetting roll A3 servingvto coat the chain threads With a cementing or bonding material from trough 4, and, as the case may i6 in the same ingfcylinder. .Such an arrangement is, vfor instance, illustrated in Fig. 26. The chain threads 2 pass in this case in the usual manner Vfrom chain beam carrier over a return roll 5-and as lower edge of theworking cylinder I6 a bonding material-trough-Ais provided carrying the return occurs will not be and return rolls e5, are then Wound over-the .1"

Vthreads l2, is accorti' tional dieiculties;

ing and-bonding together oflthe threads.

h *t plane unfolded band or vrib -from Fig. 27, which rsho path of travel voiftheftzut-Y f i. 60'

10 rolls 3. When the chain threads are passed over these return rolls. they are coated with bonding After the tube has been cut, as heremabove described such as heam 50.

In order topermit an exchange of the unreeled weftbveam'for a newly reeled beam, the weft beam is provided .with a retractable shaft 52.

according to Fig. 2., the dryorbonding agent and thus eft" In the embodiment ing ofthe cementing the-bonding or" the W which may be most Asuch as by way of the By separating the drying In-lieu of accomplishi r drying by drying cylinder 62, itk-is sometimes fof advantage,

This e t4, preferably mounted rotatably uponthe'sa shaitzwhich effects the rotation of the rotating thread Vguide 5 l AThefurther construction'of the machine correvspends essentially to that lshown n'FigsA and 7.

threads so' thata su is obtainedfwh'ich'f 1s conti nuously moved 4avv/ay by roll 25, theV toured thata ,Y su obtained for all Yc Aai the particularf'paty threads -havetoz-travers'e.ir to roll 25 may lloe different from case to case.

tating thread guidef which passes the chain threads onto the Working cylinder I6 in the form of a tubular arrangement, that it is axially rotatable into any desired fixed position.

The band or ribbon reeled off roll is passed as illustrated in Fig. 8 through printing rollers t5 which print a pattern upon the strip of chain threads carrying the transversely arranged Weit threads. inasmuch as the chain threads are positioned in this portion of the machine at an appreciably greater distance from each other than they will eventually assume in a nished carpet, it is necessary to provide the pattern on the printing rollers in appropriately distorted or elongated form. Fig. 29a shows the pattern Sila in the form in which it will be printed upon the moving chain thread strip, While Fig. 29h shows the same pattern Bib as it will appear in the nished carpet. Fig. 29a shows clearly that it is necessary by reason of the continuous movement of the chain thread curvature to those lines which are to appear as straight lines in the finished pattern so as to compensate for the continuous sluiting o the strip. This, however, is true only for such lines ci the pattern which are not exactly located in the direction of travel oi the chain thread strip.

An applicator device e8 is provided beyond printing rolls G6 as is illustrated in the embodiment oi the device in accordance with Fig. 8, for the purpose oi applying to the continuously moving chain thread strip a finishing or sizing material, and preferably of the cation-active soap type, in order to secure a substantially permanent lifting of the Weit tuiting or pile in the heated guide channels 32.

The chain thread strip printed and impregnated in this manner is now cut into strips as illustrated in accordance with the above described embodiment of the device, the cutting being effected by Way of the cutter 'or knife roll 2E lengthsides of each chain thread, whereupon the same is passed over the guide roll 28, preferably provided with Wedge channels or grooves, thence passing to the guide channels 32 which are preferably heated as above set `forth. rhe lifting or turning of the weit thread pile or tuiting is obtained in the latter, and in this manner the formation oi the chenille fur 331 occurs.

The chenille urs are then bonded or cemented upon the carpet base 35 upon the drum 34 as previously described, the base being reeled oli supply roll 3S passing on its way a coating or impregnating roll 3e serving to coat the surface of base 35 with bonding material or agent contained Within trough fill. Roll l is used for pressing the chenille furs upon the base in order to achieve a good bonding thereof. The iinished carpet product is finally Wound onto supply reel le, and, ii necessary, by way of the further counter-directional guide rolls es. For the purpose of avoiding the turning back oi the chain threads over working cylinder i6, a further alternative embodimenof the head of the device may be used as is, ior instance, illustrated in Fig. 3. This embodiment is provided with the hollow shaft 'il oi the Wedge spool beam. Chain threads 2 reeling ori chain beam i in the usual manner by way of the return roll 5, and which, as has been previously described, may be coated with a bonding or cementing material, are then passed through this hollow shait 'H being thence passed through the circular thread guide l2, secured to the back side of the hollow shaft, in the shape of a tubular arrangement of threads surrounding the rotary shaft 52. The emerging chain threads strips to impart a certain are then passed in the before-described manner' through the circular thread guide 6 onto the surface of the Working cylinder It and are here Wound with the weit treads l? as hereinabove illustrated. Similar to the embodiment shown in Eig. 2, a heating cylinder E2 having the heating coils is arranged beyond the working cylinder i6. The tubular fabric formed is then cut by ivay oi the knife member 2d in the same manner herein previously described. The further working up oi the opened ribbon or web obtained in this manner is similar to that exemplified in connection with Figs. 7 and 3.

inasmuch as the Width oi the machine cannot he varied to any desired extent if a positive guidance ci the chenille iur strip is to be obtained, there may be arranged in accordance with the invention, a multiple number oi chenille fur strips `for the purpose of obtaining any desired width oi carpet products, the strips being brought together upon a single base from several individual chenille iur strip-making units. Fig. 30 illustrates diagrammatically the passage oi multiple chenille iur strips 33d, 33h, and 33o onto a common bonding drum Inasrnuch as in this embodiment individual chenille iur strips have to be passed onto the bonding drum from the side and with a certain curvature, it is of advantage to so arrange the construction that the chenille iur strips may be 'fed from diilerent heights to the common bonding drum 35i. Such a construction is diagrammatically illustrated in Figs. 3l and 32. The chenille iur strips 33a, 33h, and 33C which come from separate units arranged at different heights, are passed in immediate adjacency to each other upon the bonding drum 34. As is apparent from the illustration, almost any desired carpet Width may be obtained in this manner.

A further alternative ufacture of Wide carpet construction for the manproducts is shown in Fig. 33. The bonding drum elli is here continuously shifted sidevvise during its rotation by Way of a pin or spike 'i3 so that the chenille iur strip 33 is spirally Wound around roll 3d. Also, with this arrangement, carpets of any desired practical Width may be obtained. it is then necessary to out the finished carpet product lengthsides ci the roll and the length of such a carpet depends upon the circuinierence of the roll, for which any desired diameter may be selected.

We claim:

l. "in the manufacture o chenille fabrics the improvement which comprises continuously moving a tubularly arranged chain ci Warp threads, continuously winding a weit thread in a substantially 'fixed path around the moving tube of chain threads and. into contact therewith, continuously applying bonding material to at least one of said chain threads and said weft thread prior to said contact, continuously cutting substantially parallel to the chain threads the continuously moving tubular fabric formed, continuously opening the moving cut portion and continuously cutting said weft thread between each adjacent chain thread.

2. improvement in accordance with claim l in which said open portion is continuously cut between each two adjacent chain threads to leave cut weft ends extending from both sides of each chain thread and in which said weft ends are substantially continuously turned towards each other in planes substantially normal to their chain thread to thereby substantially form strips oi chenille fur.

3. Improvement according to claim 2 in which said warp threads are continuously coated with said bonding material prior to said Winding.

4. Improvement according to claim 3 in which said weft thread is continuously pressed into bonding contact with said warp threads.

5. Improvement according to claim 4 in which setting heat for said bonding material is supplied during said winding.

6. Improvement according to claim 5 in which setting heat is supplied during said turning of the weft ends towards each other.

7. Improvement according to claim 3 in which wire 1s continuously moved with and stantially prevent shifting of chain threads during the winding thereof.

E). Device for the continuous manufacture of chenille fabrics which comprises substantially travel for such warp threads aggregating a substantially tubular pattern, weft thread guide means dri'vingly rotatable around said tubular pattern and defining a path of travel for winding weft thread around and in contact with any Warp threads passing along said paths, bonding material supplying means positioned for applying weft threads prior to said Contact thereof, first cutting means positioned along the periphery of said tubular pattern beyond said weft thread guide means and dimensioned for longitudinally second cutting means following said rst cutting means, and

i weft ends thread and positioned along the of travel dened for such warp of each warp further path threads.

Warp threacL support within said tubular pattern, in which said weft thread guide means are positioned for rotation around said support, in which said warp thread guide means are so positioned 11. Device in accordance with claim in which said weft thread guide means are mounted said tubular pattern.

12. Device in accordance fabric opening means are with claim 11 in which provided between said Cil first and second cutting means being positioned and dimensioned to substantially open cut tubular fabric into substantially open web form.

said support to press wound weft thread into bonding contact with warp threads.

14. Device in accordance with claim 13 in which said bonding material supplying means include means defining a substantially annular annular' supply chamber surrounding said ring of multilpe apertures in now communication with cach aperture of said ring and positioned to precede said multiple guide means for multiple warp threads.

l5. Device in accordance with claim 13 in which said bonding material supplying means include means dening a chamber, defining a 17. Device in accordance with claim 13 in substantially endlessly multiple metal thread is provided as part of said tubular and in which means are warp threads.

18. Device in accordance with claim 13 in which said fabric opening means include at least one fabric opening roll. 19. Device in accordance which said secondcutting means include a roll provided with multiple cutting blades spaced and positioned on said roll and in number surncient for cutting action in between each 2 adjacent Warp threads.

claim 20 in include heatable 27. Device in accordance with .claim in which said heating means include such means positioned within said tubular pattern following said support. 1

28. Device in accordance with claim 27 in which said heating means include a surface heatable drum substantially coaxial to the axis of said tubular pattern and dimensioned for peripheral contact relation to Warp threads moving along said paths.

29. Device in accordance with claim 27 in which said heating means include hot air dispensing means mounted rotatable within said tubular pattern..

30. Device in accordance with claim 13 in which a fabric guide member is interposed between said rst cutting means and said fabric opening means for surface contact ofvv the cut fabric therewith on its way from said rst cutting means to said fabric opening means, and in which the fabric contacting surface defined by said fabric guide means is contoured for substantial compensation of length differentials of the fabric between said rst cutting and fabric opening means.

31. Device in accordance with claim 30 in which said fabric opening means include a fabric opening roll.

32. Device in accordance with claim 13 in which a second rotatable member is provided opposite said first rotatable member, in which means are provided for moving said second rotatable member into operating position for weft thread guidance and moving said first rotatable member outof such position upon emptying of weft thread spool thereon.

33. Device in accordance with claim 32 in which means are additionally provided for connecting the reeled-off end of any weft spool thread on said first rotatable member to the weft thread beginning of a corresponding spool on said second rotatable member.

34. Device in accordance with claim 10 in which said weft thread guide means are mounted on a drivingly rotatable member, in which at least one substantially stationary weft thread spool carrier is mounted in the direction of the head of said support in weft thread supplying relation to its guide means on said rotatable member, in which said member is mounted for rotation of said guide means along a substantially fixed path of travelin a plane about normal to the axis of said tubular pattern', and in which fabric opening means are provided between said iirst and second cutting means being positioned and dimensioned to substantially open out tubular fabric into substantially open web form.

35. Device in accordance with claim 10 in which said weft thread guide means are mounted on a drivingly rotatable member, in which multiple weft thread spool carriers are rotatably mounted on a weft beam positioned substantially on the same axis as that of said tubular pattern over said support, said spool carriers being mounted in weft thread supplying relation to its guide means on said rotatable member, in which said member is mounted for rotation of said guide means along a substantially fixed path of travel in a plane about normal to the axis of said tubular pattern, and in which fabric opening means are provided between said first and second cutting means being positioned and dimensioned to substantially open cut tubular fabric into substantially open web form.

36. Device in accordance with claim in which said weft beam is a substantially hollow weft beam, and in which means are provided for guiding multiple chain threads into the interior of said weft beam.

37. Device in accordance with claim 35 in which said support substantially defines a cylindrical surface with its axis positioned substantially vertically and in which said weft beam is downwardly retractably mounted.

38. Device in accordance with claim 13 in which said support defines a substantially hollow cylinder, in which means are provided for passing multiple warp threads through the interior of said cylinder, in a direction opposite the direction of travel thereof over said support, and in which means are provided for reversing the direction of travel of said chain threads emerging from said hollow cylinder by about 39. Device in accordance with claim 20 in which printing rolls are additionally provided following said heatable channel means for continuously printing carpet-making patterns onto the same.

References Cited in the file of this patent UNITED STATES PATENTS 

